Orthopedic brace having length-adjustable supports

ABSTRACT

An orthopedic brace having length adjustable supports is provided. The brace comprises upper and lower supports rotatably connected by a hinge. Each of the supports comprises an elongate portion having a channel along part of its length, and a sliding upright that nests within the channel. The upright is incrementally longitudinally translatable within the channel so that the length of the support is adjustable. Flanges are provided along the edges of the channel to prevent lateral separation of the upright from the stationary portion. A spring-biased button protrudes from an upper surface of the channel. The button cooperates with one of a plurality of holes in the upright, providing a positive lock to retain the upright in one of a number of predetermined positions within the channel. The upright is also completely removable from the channel. Removal of the upright from the channel shortens the brace. Straps cooperate with brackets on the supports and/or uprights to secure the brace to a patient&#39;s leg.

RELATED APPLICATION

This application claims priority to provisional application Ser. No.60/255,521, filed on Dec. 12, 2000.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to orthopedic braces and, moreparticularly, to orthopedic braces having length adjustment capability.

2. Description of the Related Art

Orthopedic braces are commonly employed after surgery or for treatmentof injury to a joint. Such braces generally serve to stabilize thejoint. In certain cases orthopedic braces limit joint flexion and/orextension in a controllable and adjustable manner to prevent re-injuryof the joint and to promote rehabilitation.

Some prior art orthopedic braces include length-adjustable supportmembers. However, these braces typically comprise sidebar componentsthat are merely sandwiched together. This configuration makes themsusceptible to prying forces that tend to separate the components.

In addition, some prior art braces use threaded fasteners to connect thesidebar components. Adjusting these braces requires a screwdriver orturning a manual thumbscrew, both of which are inconvenient and timeconsuming. Such braces are also typically prone to failure due tostripped fastener threads. Other braces rely upon friction, as fromtightening a lead screw, to hold the components of the brace in thedesired position. These braces, however, do not provide a positive lock,and are thus prone to disadvantageous slippage.

Some prior art braces use an all-aluminum construction. Machining andforming aluminum, however, is relatively expensive and has certainphysical limitations. Aluminum thus limits the range of features andstyle that may be incorporated into the brace.

SUMMARY OF THE INVENTION

The preferred embodiments of the orthopedic brace have several features,no single one of which is solely responsible for their desirableattributes. Without limiting the scope of this orthopedic brace asexpressed by the claims that follow, its more prominent features willnow be discussed briefly. However, not all of the following features arenecessary to achieve the advantages of the orthopedic brace. Therefore,none of the following features should be viewed as limiting. Afterconsidering this discussion, and particularly after reading the sectionentitled “Detailed Description of the Preferred Embodiments,” one willunderstand how the features of the preferred embodiments provideadvantages over prior braces. One such advantage is length adjustabilityso that the amount of restraint offered by the brace may be alteredduring a course of treatment and so that one brace may fit differentlysized patients. Another advantage is that the brace includes a lowprofile that prevents the brace from snagging objects as the wearermoves about. The brace may be manufactured from a combination ofthermoplastic composite and metal that enables the brace to harness theadvantages of both materials. Further, the brace may have a lengthadjustment mechanism that is recessed to prevent accidental activation.

One preferred embodiment of the orthopedic brace comprises a firstsupport, a second support, and a hinge assembly rotatably connecting thefirst and second supports. At least one of the first and second supportscomprises an outer portion defining a longitudinal channel and atelescoping upright movable in the channel to adjust a length of thesupport.

In another preferred embodiment, at least one strap is provided to wraparound the brace and a patient's leg to secure the brace to the leg.

In another preferred embodiment, at least one padded cuff is disposedbetween the patient's leg and the brace to increase patient comfort.

In another preferred embodiment, the upright is removable from the atleast one of the first and second supports to shorten the overall lengthof the brace.

In another preferred embodiment, a plurality of engagement surfaces areprovided along a length of the telescoping upright, and the outerportion includes an engagement member selectively engageable with theengagement surfaces to lock the telescoping portion in place in thechannel.

In another preferred embodiment, the engagement member is recessedwithin the upright when the engagement member engages one of theengagement surfaces.

In another preferred embodiment, the engagement member comprises abutton disposed within a recess in the channel and biased toward aconfiguration wherein a portion of the button protrudes from a surfaceof the channel.

In another preferred embodiment, the button has an oval shape in planaspect.

In another preferred embodiment, the engagement surfaces comprise holes.

In another preferred embodiment, the holes have an oval shape in planaspect.

In another preferred embodiment, the first and second supports arecurved about an axis that is parallel to a longitudinal axis of thebrace.

In another preferred embodiment, a cross-section of the first and secondsupports includes a first region having a first radius of curvature anda second region having a second radius of curvature longer than thefirst radius of curvature.

In another preferred embodiment, the first region is located between thesecond region and a third region having the second radius of curvature.

In another preferred embodiment, the first and second supports furthercomprise at least a first generally D-shaped ring on a first side and asecond generally D-shaped ring on a second side opposite the first side.

In another preferred embodiment, the first and second rings are adjacentthe hinge assembly.

In another preferred embodiment, the upright comprises at least a firstgenerally D-shaped ring on a first side and a second generally D-shapedring on a second side opposite the first side.

In another preferred embodiment, the first and second rings are locatedat an end of the upright opposite the hinge assembly.

In another preferred embodiment, the hinge assembly comprisesflexion-limiting stops.

In another preferred embodiment, the hinge assembly comprisesextension-limiting stops.

In another preferred embodiment, the orthopedic brace comprises a firstsupport, a second support, and a hinge assembly rotatably connecting thefirst and second supports. At least one of the first and second supportscomprises a first portion constructed of a thermoplastic composite and asecond portion constructed of a metal.

In another preferred embodiment, the first portion comprises an outerportion defining a longitudinal channel.

In another preferred embodiment, the second portion comprises atelescoping upright movable in the channel to adjust the length of thesupport.

In another preferred embodiment, the first portion is connected to ametal hinge plate.

In another preferred embodiment, the hinge plate is insert molded withinthe first portion.

In another preferred embodiment, a portion of the hinge plate isbendable about an axis that is perpendicular to an axis of rotation ofthe hinge assembly.

In another preferred embodiment, the orthopedic brace comprises a firstlength-adjustable support and a second length-adjustable support. Eachsupport includes a longitudinal channel and a sliding upright within thechannel. A hinge assembly rotatably connects the first and secondsupports. Each sliding upright includes a plurality of through holes,and a floor of each channel includes a spring-biased button. The buttonis engageable with each hole such that the button positively locks aposition of the upright with respect to the channel. The upright isslidable within the channel when the button is depressed.

In another preferred embodiment, each support includes a curvature abouta longitudinal axis thereof such that substantially all of a surface ofeach support that faces a patient's leg contacts the leg.

In another preferred embodiment, each support further comprises aplurality of brackets that are adapted to receive flexible straps forsecuring the brace to a patient's leg.

BRIEF DESCRIPTION OF THE DRAWINGS

The preferred embodiments of the orthopedic brace, illustrating itsfeatures, will now be discussed in detail. These embodiments depict thenovel and non-obvious orthopedic brace shown in the accompanyingdrawings, which are for illustrative purposes only. These drawingsinclude the following figures, in which like numerals indicate likeparts:

FIG. 1 is a perspective view of a preferred embodiment of the orthopedicbrace of the present invention including a right support and a leftsupport, padded cuffs and straps;

FIG. 2 is a partially exploded perspective view of the brace and paddedcuffs of FIG. 1;

FIG. 3 is a perspective view of another preferred embodiment of theorthopedic brace including a right support;

FIG. 4 is an exploded perspective view of a calf portion of the brace ofFIG. 3;

FIG. 4A is a partially exploded perspective view of the calf portion ofFIG. 4;

FIG. 5A is a top plan view of a link bar of a thigh portion the brace ofFIG. 3;

FIG. 5B is a bottom plan view of the link bar of FIG. 5A;

FIG. 5C is a right-side elevation view of the link bar of FIG. 5A;

FIG. 5D is a front elevation view of the link bar of FIG. 5A;

FIG. 5E is a detail view of a recess portion of the link bar of FIG. 5A;

FIG. 6A is a top plan view of a link bar of a calf portion the brace ofFIG. 3;

FIG. 6B is a bottom plan view of the link bar of FIG. 6A;

FIG. 6C is a right-side elevation view of the link bar of FIG. 6A;

FIG. 6D is a front elevation view of the link bar of FIG. 6A;

FIG. 7A is a top plan view of a hinge plate of the link bar of FIG. 5A;

FIG. 7B is a right-side elevation view of the hinge plate of FIG. 7A;

FIG. 8A is a top plan view of a hinge plate of the link bar of FIG. 6A;

FIG. 8B is a right-side elevation view of the hinge plate of FIG. 8A;

FIG. 9A is a top plan view of a sliding upright of a calf portion of thebrace of FIG. 3;

FIG. 9B is a bottom plan view of the sliding upright of FIG. 9A;

FIG. 9C is a front elevation view of the sliding upright of FIG. 9A;

FIG. 9D is a right-side elevation view of the sliding upright of FIG.9A;

FIG. 9E is a left-side elevation view of the sliding upright of FIG. 9A;

FIG. 10A is a top plan view of a sliding upright of a thigh portion ofthe brace of FIG. 3;

FIG. 10B is a bottom plan view of the sliding upright of FIG. 10A;

FIG. 10C is a front elevation view of the sliding upright of FIG. 10A;

FIG. 10D is a right-side elevation view of the sliding upright of FIG.10A;

FIG. 10E is a left-side elevation view of the sliding upright of FIG.10A;

FIG. 11 is a perspective view of a preferred embodiment of theorthopedic brace including a right support and a left support, paddedcuffs and straps, wherein sliding uprights of each support have beenremoved; and

FIG. 12 is a partially exploded perspective view of the brace and paddedcuffs of FIG. 11.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIGS. 1 and 2 illustrate a preferred embodiment of an orthopedic brace20. In the illustrated embodiment, the orthopedic brace 20 is a kneebrace. However, one of skill in the art will appreciate that certainfeatures of the orthopedic brace 20 are applicable to other types ofbraces as well, such as arm braces, ankle braces, neck braces, and thelike.

The embodiment of FIGS. 1 and 2, which is adaptable for use on eitherthe left or the right leg of a patient, comprises a first elongatesupport 22 for positioning along the right side of the patient's leg,and a second elongate support 24, for positioning along the left side.If desired, only one support may be used for particular applications. Inthe two support configuration, however, the two supports 22, 24preferably are mirror images of one another.

The supports 22, 24 are secured to a patient's leg with straps 26 thatwrap around the circumference of the leg. In the embodiment illustratedin FIG. 1, six straps 26 are provided. Those of skill in the art willappreciate, however, that fewer or more straps may be used. A pluralityof padded cuffs 28 disposed between the supports 22, 24 and the legprovide padding and increase patient comfort. Those of skill in the artwill also appreciate that the cuffs 28 merely enhance the wearability ofthe brace 20, and are not an essential component of the brace 20. A pad30 may be secured to an inside surface of each support 22, 24 near amidpoint of each support 22, 24. In a preferred embodiment, the cuffs 28and pads 30 each comprise a layer of foam padding and a layer of a loopportion of a hook-and-loop fastener.

In another preferred embodiment, an inside surface of the cuffs 28and/or pads 30 comprises a fabric. This surface contacts the patient'sleg. Therefore, the fabric is preferably any material that iscomfortable for wear against the skin. A preferred material is nylon. Ofcourse, the cuffs need not include a fabric layer on an inside surface.Preferably, however, the cuffs do not irritate the patient's skin.

The loop portion of a hook-and-loop fastener forms an outside surface ofthe cuffs 28 and pads 30. The outside surface contacts a plurality ofinserts 32 which may be disposed between the cuffs 28 and pads 30 andthe supports 22, 24. A first face of each insert comprises a hookportion of a hook-and-loop fastener and faces the outside surface of thecuffs 28 and pads 30. A second face, opposite the first face, adhesivelyattaches the inserts 32 to the inside surfaces of the supports 22, 24.The inserts 32 thus removably secure the supports 22, 24 to the cuffs 28and pads 30 to prevent migration of the brace 20 relative to the cuffs28 and pads 30. Rather than including the inserts 32, a variety of otherconfigurations could be used to maintain the relative positions of thebrace 20 and cuffs 28. For example, fasteners other than hook-and-loopcould be used. Alternatively, the cuffs could be manufactured fromneoprene, or another material that has a high coefficient of staticfriction.

FIG. 3 illustrates the right support 22 in detail. In the illustratedembodiment, the support 22 includes a thigh portion 34 and a calfportion 36. A hinge portion 38 rotatably connects the thigh portion 34and calf portion 36. The hinge portion 38 may comprise any of a varietyof well-known hinges. However, examples of preferred hinge types aredescribed in U.S. Pat. Nos. 5,921,946 to Tillinghast, and 5,443,444 toPruyssers, the entirety of which are incorporated herein by reference.

FIG. 4 is an exploded perspective view of the calf portion 36 of theright support 22. The thigh portion 34 is substantially identical to thecalf portion 36, with a few exceptions. The calf portion 36 preferablycomprises a link bar 39, a sliding upright 40, and a button 42. Whenassembled, the button 42 nests inside the link bar 39, as describedbelow.

The link bar 39 in turn is constructed of two pieces, as shown in FIGS.5A-5E and 6A-6D. A first piece, or hinge plate 44, 48, is fixedlyconnected at a first end to a second piece, or channel member 46. Eachof the thigh portion 34 and calf portion 36 includes an identicalchannel member 46. A second end of the hinge plate 44, 48 is rotatablyconnected to the hinge portion 38 (FIG. 3). In the embodiment shown, theshape of the hinge plate 44 comprising the thigh portion 34 differs fromthe shape of the hinge plate 48 comprising the calf portion 36. Theshapes and functions of the hinge plates 44, 48 are described in detailin the above-referenced patent to Tillinghast.

FIGS. 7A-8B illustrate preferred embodiments of the hinge plates 44, 48.Each hinge plate 44, 48 includes a base portion 50 that is secured tothe corresponding channel member 46, and an extended portion 52, 54 thatis disposed adjacent the channel member 46. The base portion 50 may beembedded within the channel member 46, or may be secured to the channelmember 46 in another appropriate fashion, such as with bolts or rivets.The base portion 50 of each hinge plate 44, 48 is a flat, substantiallyrectangular plate preferably having at least one through hole 56 and atleast one notch 58 along a side 60 thereof.

Referring to FIG. 8B, the extended portion 52 of the calf hinge plate 48includes a ramp portion 62 that extends at an angle from the baseportion 50, and a second flat, substantially rectangular plate 64 thatlies in a plane that is substantially parallel to that of the baseportion 50. The extended portion 54 of the thigh hinge plate 44 (FIGS.7A and 7B) comprises an oblong flat plate 66 extending at an angle fromthe base portion 50. The plate 66 preferably has a multi-contoured edge68 that includes a plurality of cammed surfaces 70, extension limitinglands 72, and flexion limiting lands 74. The surface of the plate 66includes a through bore 76 near an end of the plate 66 opposite the baseportion 50, at least one elongate trough 78 extending substantially inthe lengthwise direction of the plate 66, and a stepped slot 80extending in substantially the same direction. The surface features ofthe hinge plates 44, 48 facilitate the operation of the hinge 38, whichis described in detail in the above-referenced patent to Tillinghast.

The hinge plates 44, 48 are preferably constructed of aluminum or otherpliable metal. Because of the wide variety of shapes and sizes of humanlegs, it is advantageous for a treating physician to be able to readilybend the knee brace 20 to more comfortably and effectively fit thecontours of the leg. Aluminum and other pliable metals are relativelyeasy to bend by hand. These metals thus advantageously provideformability to the knee brace 20.

In the embodiment illustrated in FIGS. 5A-5E and 6A-6D, the channelmember 46 is shaped as an elongate bar, having an integral,substantially D-shaped bracket 82 near each corner thereof. The brackets82 project outwardly from the sides 84 of the channel member 46. Eachbracket 82 defines a central slot 86 that is adapted to receive one ofthe straps 26. The straps 26 cooperate with the brackets to secure thebrace 20 to the patient's leg.

A recess 88, elliptical in plan aspect, is provided in a floor 90 ofeach channel member 46 near an end 92 of the channel member 46 oppositethe hinge plate 44, 48. The recess 88 houses the button 42 (FIG. 4),which is sized and shaped to fit within the interior of the recess 88. Aspring 94 is disposed around a post 96 within the recess 88. A first endof the spring 94 abuts a lower surface of the button 42, and a secondend of the spring 94 abuts a floor of the recess 88. The spring 94 thusbiases the button 42 outwardly from the interior of the recess 88, suchthat an upper portion of the button 42 protrudes from the recess 88(FIG. 4A). Retaining tabs 98 on the lower end of the button 42 extendthrough holes 100 (FIG. 5E) in the channel member 46 and prevent thebutton 42 from being completely expelled from the recess 88.

An inner surface 102 (FIGS. 5B and 6B) of the channel members 46 restsagainst the padded cuffs 28 when the brace 20 is worn. The inner surface102 is preferably curved in cross-section to more closely fit the curvedsurface of the leg. The curvature helps to prevent the supports 22, 24from shifting relative to the cuffs 28. An outer surface 103 (FIG. 5Cand 6C) is also preferably curved in cross-section. The curved outersurface 103 gives the supports 22, 24 a more streamlined appearance,thereby reducing the risk that the supports 22, 24 will snag objectswhen the patient engages in physical activity. Those of skill in the artwill appreciate that the supports 22, 24 need not include any curvature.Supports having substantially flat cross-sections do not depart from thespirit of the brace 20.

In a preferred embodiment, the inner surface 102 of the channel member46 includes portions having different radii of curvature. The centerportion 104 of the inner surface, as viewed from the side (FIGS. 5C and6C), has a relatively short radius of curvature, while the outerportions 106 on either side of the center portion 104 each have a longerradius of curvature. The larger radius is selected to conform to thecurved surface of the leg in order to increase patient comfort andprovide a streamlined profile for the brace 20. The smaller radius ofcurvature of the center portion 104 increases the rigidity, or bendingstrength, of the channel member 46 without adding additional material.Additional material would tend to increase the weight of the channelmember 46 and compromise its low profile. The small-radius centerportion 104 also creates a gap between the center portion 104 of theinner surface 102 and the outer surface of the cuffs 28. This gapprovides room for the inserts 32 and enables the button 42 to bedepressed more easily while the brace 20 is worn. Without the gap, theretaining tabs 98 (FIG. 4) may interfere with the cuffs 28 when thebutton 42 is depressed.

The floor 90 of each channel member 46 is preferably similarly curved,and includes a pair of oppositely disposed flanges 108 at the sidesthereof. The flanges 108 extend along most of the length of the channelmember 46, creating a channel 110 that is substantially C-shaped in anend view (FIGS. 5C and 6C). The channel 110 has an open top. A first end112 (FIGS. 5A and 5C) of the channel 110 near the hinge plate 44, 48 isclosed, while a second end 92 of the channel 110 opposite the first end112 is open.

The channel members 46 (FIGS. 5A and 6A) are preferably constructed of acomposite material, and are formed by an insert molding process. Acomposite consisting of 83% thermoplastic nylon and 17% glass is aparticularly preferred material for the channel members 46. During theinsert molding process, the base portions 50 of the hinge plates 44, 48are placed in an insert mold, after which a liquid composite is injectedinto the mold. The liquid composite surrounds the base portions 50,filling the holes 56 and notches 58. The composite that fills the holes56 and notches 58 greatly strengthens the connection between the hingeplates 44, 48 and channel members 46 by increasing the pull-out strengthof the hinge plates 44, 48. Rather than securing the hinge plates 44, 48to the channel members 46 by an insert molding process, otherconventional methods of attachment could be used. For example, screws orrivets may be used to secure the hinge plates 44, 48 to the channelmembers 46.

The combination of metal and composite in the supports 22, 24 impartsseveral advantages to the brace 20. First, insert molding is arelatively inexpensive process that enables complicated geometries to beformed with ease. Thus, even the complex shape of the channel members46, which have contoured surfaces, ridges and tight interior comers, canbe manufactured at relatively low cost. Surfaces and shapes such asthese could not reasonably be formed from metal, at least not withoutundesirable additional cost. Second, the use of a bendable metal allowsthe brace 20 to be custom formed by a physician to fit the exactcontours of the patient's leg. Thus, providing a link bar 39 (FIGS. 5Aand 6A) that is formed from both metal and thermoplastic compositeallows preferred embodiments of the brace 20 to include both of theseadvantages, rather than just one or the other.

A preferred embodiment of the sliding upright 40 is illustrated indetail in FIGS. 9A-9E. A second sliding upright 114, illustrated indetail in FIGS. 10A-10E, is substantially identical to the upright 40,except that the upright 40 includes an extension section 116 such thatthe upright 40 is longer than the upright 114. The difference in lengthsbetween the upright 40 and upright 114 enables the brace 20 to betterfit the patient's leg. Those of skill in the art will appreciate,however, that uprights of any suitable length, including uprights havingequal lengths, are within the scope of the present orthopedic brace 20.

The uprights 40, 114 comprise an elongate bar with a pair of brackets118 at one end thereof. The uprights 40, 114 nest within the channelmembers 46 of the calf portion 36 and thigh portion 34, respectively.The brackets 114 are similar in size, shape and orientation to thebrackets 82 of the channel members 46, and are designed to receive thestraps 26 within a central slot 120 for securing the brace 20 to thepatient's leg. A center of an end 119 of each upright 40, 114 adjacentthe brackets includes an indentation 121. The indentations 121 increasepatient comfort by preventing interference between the sliding uprights40, 114 and the patient's malleoli. Those of skill in the art willappreciate that the indentations are not necessary to achieve theobjects of the orthopedic brace 20.

Each of the uprights 40, 114 has a curved cross-section (FIGS. 9D-9E and10D-10E) of substantially the same radius as the floor 90 of the channelmember 46. The curved contour not only allows the uprights 40, 114 tofit within the channels 110, but it also provides the uprights 40, 114with greater rigidity. As with the channel members 46, discussed above,the uprights 40, 114 need not be curved in cross-section. Preferably,however, the uprights have appropriate cross-sectional shapes to fitwithin the channels in the channel members. The uprights 40, 114 mayalso be provided with a cross-section of variable thickness, if desired,to further increase the stiffness of the uprights 40, 114.

The thickness of the uprights 40, 114 near the edges 122 thereof allowsthe uprights 40, 114 to fit beneath the flanges 108 of the channelmembers 46. The uprights 40, 114 are thus configured to enter the openends 92 of the channels 110 and slide longitudinally within the channels110. The flanges 108 extend over the edges 122 of the uprights 40, 114to prevent lateral separation of the uprights 40, 114 from the channelmembers 46. The slidability of the uprights 40, 114 within the channels110 allows the length of the brace 20 to be adjusted.

Each of the uprights 40, 114 contains a plurality of spaced-apartelliptical holes 124 along a longitudinal axis thereof. The holes 124desirably have substantially the same size, shape and orientation as thebutton 42. As the uprights 40, 114 slide within the channels 110, theholes 124 consecutively pass over the button 42. As each hole 124passes, the biasing spring 94 forces the button 42 into the hole 124.The button 42 prevents further translation of the uprights 40, 114through the channels 110, until an operator depresses the button 42 andholds it down while translating the uprights 40, 114 within the channels110. The button 42 and corresponding holes 124 may be of any suitableshape.

The relatively large size and elliptical shape of the holes 110 and thebutton 42 allow the button 42 to be easily actuated by a finger or thumbof the operator. This configuration greatly reduces the difficulty ofadjusting the brace 20, because the operator has one hand free tomanipulate the uprights 40, 114 while holding down the button 42 withthe finger or thumb.

When the button 42 is disposed within a hole 124, a top surface 126(FIG. 4) of the button 42 is preferably flush with, or recessed below,the outer surface of the uprights 40, 114 as in FIG. 3. This arrangementreduces the risk that the button 42 will be accidentally activated ifthe wearer, for example, bumps into a table or chair.

The length adjustability of the brace 20, having push-button activation,provides the brace 20 with a number of advantages. First, the brace 20is adapted to fit a wide variety of patients without the need forcomplicated adjustments. To fit the brace 20 to a patient, a physicianindividually adjusts the length of the thigh portion 34 and calf portion36. The adjustment procedure for each portion 34, 36 is substantiallyidentical, and the physician may adjust the portions 34, 36 in anyorder. To illustrate, however, adjustment of the thigh portion 34 willbe described.

The physician depresses the button 42 by applying pressure to the buttontop surface 126 (FIG. 3) with his or her thumb or finger. When at leasta leading edge of the button top surface 126 is below the hole 124, theupright 114 is freely translatable within the channel 110 (FIG. 5C) ineither direction. Because the button 42 is biased outwardly by thespring 94 (FIG. 4), as the physician translates the upright 114 thebutton 42 will automatically pop into each successive hole 124 as eachpasses over the button 42, thereby locking the upright 114 in place withrespect to the channel member 46. Each time the button 42 pops out, thephysician pushes it back in and continues translating the upright 114until the button 42 pops into the desired hole 124. When the button 42pops into the desired hole 124, the upright 114 is securely locked withrespect to the channel member 46.

Second, since preferred embodiments of one brace 20 will fit manypatients of different sizes, hospitals need not maintain a largeinventory of differently sized braces. With some prior art braces,length adjustment effectively means substituting a brace of one sizewith a differently sized brace. Thus, hospitals must maintain a largeinventory of braces of all different sizes in order to accommodate thewide variety of patients that they regularly treat. With preferredembodiments of the brace 20, hospitals need only keep a supply of onebrace 20. Physicians then adjust the length of the brace 20 as needed tofit individual patients.

Third, as the patient progresses through therapy, it is often desirableto reduce the amount of support provided by the brace 20, such as byshortening the length of the brace 20. With preferred embodiments of thebrace 20, however, the uprights 40, 114 may be retracted to decrease theoverall length of the brace 20. Alternatively, if an even shorter brace20 is desired, one or both uprights 40, 114 may be completely removedfrom their respective channels 110. The remaining length of the supports22, 24, which consists of the link bars 39 and the hinge portion 38, maythen be used in isolation, as shown in FIGS. 11 and 12. Removal of theuprights 40, 114 is quick and easy, requiring only that the button 42 bedepressed while the uprights 40, 114 are drawn completely out of thechannels 110. The brace 20 is thus far more versatile than prior artdesigns.

The embodiment of the brace 20 depicted in FIGS. 11 and 12 includesshells 128 disposed between the supports 22, 24 and the cuffs 28. Theshells 128 comprise semi-rigid members that aid in providing evencompression about the patient's leg. Preferably the shells 128 areconstructed of a plastic. However, any semi-rigid material could beused.

In the pictured embodiment, each shell 128 is shaped substantially as ahalf-cylinder. Thus, two shells 128 comprise a thigh-encircling portion,and two shells 128 comprise a calf-encircling portion. Those of skill inthe art will appreciate that the shells 128 may be constructed in avariety of alternative ways. For example, the thigh-or calf-encirclingportion could be shaped as a complete cylinder with a longitudinal splitso that the cylinder may be wrapped around the patient's leg. Those ofskill in the art will also appreciate that the shells 128 may be usedwith the embodiment of the brace 20 depicted in FIGS. 1 and 2. Finally,those of skill in the art will also appreciate that the shells 128 arenot necessary to achieve the objects of the orthopedic brace 20.

SCOPE OF THE INVENTION

The above presents a description of the best mode contemplated for thepresent orthopedic brace having length-adjustable supports, and of themanner and process of making and using it, in such full, clear, conciseand exact terms as to enable any person skilled in the art to which itpertains to make and use this brace. This brace is, however, susceptibleto modifications and alternate constructions from that discussed abovewhich are fully equivalent. Consequently, it is not the intention tolimit this brace to the particular embodiments disclosed. On thecontrary, the intention is to cover all modifications and alternateconstructions coming within the spirit and scope of the brace asgenerally expressed by the following claims, which particularly pointout and distinctly claim the subject matter of the brace.

What is claimed is:
 1. An orthopedic brace, comprising: a first support;a second support; and a hinge assembly rotatably connecting the firstand second supports, wherein at least one of the first and secondsupports comprises a first portion constructed of a thermoplasticcomposite and a second portion constructed of a metal; the first portionis connected to a metal hinge plate; and the hinge plate is insertmolded within the first portion.
 2. An orthopedic brace, comprising: afirst support; a second support; and a hinge assembly rotatablyconnecting the first and second supports, wherein at least one of thefirst and second supports comprises an outer portion defining alongitudinal channel and a telescoping upright movable in the channel toadjust a length of the support; and a plurality of engagement surfacesare provided along a length of the telescoping upright, and the outerportion includes an engagement member selectively engageable with atleast one of the engagement surfaces to lock the telescoping portion inplace in the channel.
 3. The orthopedic brace of claim 2, wherein theengagement member is recessed within the upright when the engagementmember engages the at least one of the engagement surfaces.
 4. Theorthopedic brace of claim 3, wherein the engagement member comprises abutton disposed within a recess in the channel and biased toward aconfiguration wherein a portion of the button protrudes from a surfaceof the channel.
 5. The orthopedic brace of claim 4, wherein the buttonhas an oval shape in plan aspect.
 6. The orthopedic brace of claim 2,wherein the engagement surfaces comprise holes.
 7. The orthopedic braceof claim 6, wherein the holes have an oval shape in plan aspect.
 8. Anorthopedic brace, comprising: a first support; a second support; and ahinge assembly rotatably connecting the first and second supports,wherein at least one of the first and second supports comprises an outerportion defining a longitudinal channel and a telescoping uprightmovable in the channel to adjust a length of the support; the first andsecond supports are curved about an axis that is parallel to alongitudinal axis of the brace; and a cross-section of the first andsecond supports includes a first region having a first radius ofcurvature and a second region having a second radius of curvature longerthan the first radius of curvature.
 9. The orthopedic brace of claim 8,wherein the first region is located between the second region and athird region having the second radius of curvature.
 10. An orthopedicbrace, comprising: a first support; a second support; and a hingeassembly rotatably connecting the first and second supports, wherein atleast one of the first and second supports comprises an outer portiondefining a longitudinal channel and a telescoping upright movable in thechannel to adjust a length of the support; and the first and secondsupports further comprise at least a first generally D-shaped ring on afirst side and a second generally D-shaped ring on a second sideopposite the first side.
 11. The orthopedic brace of claim 10, whereinthe first and second rings are adjacent the hinge assembly.
 12. Anorthopedic brace, comprising: a first support; a second support; and ahinge assembly rotatably connecting the first and second supports,wherein at least one of the first and second supports comprises an outerportion defining a longitudinal channel and a telescoping uprightmovable in the channel to adjust a length of the support; and theupright comprises at least a first generally D-shaped ring on a firstside and a second generally D-shaped ring on a second side opposite thefirst side.
 13. The orthopedic brace of claim 12, wherein the first andsecond rings are located at an end of the upright opposite the hingeassembly.
 14. An orthopedic brace, comprising: a first length-adjustablesupport including a longitudinal channel and a sliding upright slidablyengaging the channel; a second length-adjustable support including alongitudinal channel and a sliding upright slidably engaging thechannel; and a hinge assembly rotatably connecting the first and secondsupports, wherein each sliding upright includes a plurality of throughholes, and a floor of each channel includes a spring-biased buttonengageable with each hole such that the button positively locks aposition of the upright with respect to the channel and the upright isslidable within the channel when the button is depressed.
 15. Theorthopedic brace of claim 14, wherein each support includes a curvatureabout a longitudinal axis thereof such that substantially all of asurface of each support that faces a patient's leg contacts the leg. 16.The orthopedic brace of claim 14, wherein each support further comprisesa plurality of brackets that are adapted to receive flexible straps forsecuring the brace to a patient's leg.